CN111302078B

CN111302078B - Automatic stack shape changing method and device

Info

Publication number: CN111302078B
Application number: CN202010104935.XA
Authority: CN
Inventors: 邵健锋; 崔巍
Original assignee: New Trend International Logis Tech Co ltd
Current assignee: New Trend International Logis Tech Co ltd
Priority date: 2020-02-20
Filing date: 2020-02-20
Publication date: 2021-05-28
Anticipated expiration: 2040-02-20
Also published as: CN111302078A

Abstract

The invention discloses an automatic stack shape changing method and a device thereof, wherein the method comprises the following steps: when the pallets with the predictable stacking number need to be stacked, the target stacking type can be inquired according to the standard stacking type, the current stock and the stacking number, and stacking is carried out according to the target stacking type; when the pallets with unpredictable stacking quantity need to be stacked, stacking can be carried out according to a standard stack shape, and after the stacking is finished, the position of the existing goods on the pallets is adjusted to enable the goods to reach a stable stack shape; when needs chop, can chop according to tearing open and chop the quantity and chop to judge when tearing open and chop and whether present buttress type is stable buttress type, if not then carry out position adjustment to remaining goods on the tray, make it reach stable buttress type. The invention has the advantages that the middle layer is separated, the dependence on an upper layer control system is reduced, and the stacking type can be dynamically changed, so that the generation of unstable stacking type in various scenes is avoided.

Description

Automatic stack shape changing method and device

Technical Field

The invention relates to the field of warehousing, in particular to a stack type automatic transformation method and a device thereof.

Background

In an automatic warehouse with standardized packaging, a robot (an industrial mechanical arm, the same applies below) is often required to be equipped for stacking before goods are put in the warehouse and unstacking before goods are taken out of the warehouse. Palletizing means that goods are stacked on a pallet in a prescribed manner, and unstacking is reversed.

The stack shape is designed according to the stacking height and needs to meet certain industry standards. For example, the stack type may be a 30-piece stacking specification as in figure 1.

When goods are stacked at a high position, the goods may be displaced when the pallet is moved due to factors such as height, contact surface, dead weight, package slip and deformation. In order to prevent the goods from collapsing when the goods are stored in and out of the warehouse, the outer film wrapping treatment is carried out on part of the stack type (for example, 30 stack types as shown in figure 1). While a partially stabilized buttress type (e.g., such as the 28-pack type of fig. 2) does not suffer from the problems described above.

The instability of the top-level cargo is more pronounced when a less stable pallet pattern must be used according to the specifications, and because the quantity of the cargo on the pallet does not reach the optimum range for the pallet pattern. For example, when the pallet is 21 pieces of goods, as shown in fig. 1, the goods are easily collapsed and displaced because only one piece of goods stands on the third layer. While the wrapping prevents it from falling down the outside, the goods collapse or shift in other directions (e.g., to the inside of the pallet), which can still lead to robot positioning errors during unstacking. Therefore, when such a situation is encountered, it must be avoided or alleviated by a certain design.

At present, to solve the above problems, the following schemes are generally adopted:

1. the filling materials are adopted: after wrapping, the top layer blank area is filled as necessary. The disadvantage of this solution is that filling requires special equipment to be done and needs to be removed again by special equipment before the disc is dismantled. And the filler is a consumable material, which brings environmental pollution and resource use, and a finished product is used.

2. The number of the near-tail discs is changed: when the tail tray stacking type is determined to be unstable, the number of the near-tail trays is optimized, so that the unstable stacking type of the tail tray is avoided. For example, when the warehousing quantity is 51 pieces as in the 30-piece stacking of fig. 1, the number of code wheels of 30+21 is not adopted, but the number of code wheels of 23+28 pieces is adopted, and the displacement can be more effectively prevented. The defect of the scheme is that the warehousing quantity can be predicted, and the warehousing quantity cannot be predicted after production line warehousing; and when the tray is partially disassembled (for example, 30 pieces are disassembled for 9 pieces), the generation of unstable stack shape cannot be avoided.

3. Manual intervention: and after the unstable stack shape appears, manually stacking the upper-layer goods again. The disadvantage of this scheme is that the warehouse needs to be held by the order in the working time of the warehouse by manpower, and is not suitable for the requirement of the automatic warehouse; and if the pallets require robotic unstacking, the goods positions need to be manually restored again prior to unstacking.

Disclosure of Invention

The invention aims to provide an automatic stack type conversion method and a device thereof, which can avoid the generation of unstable stack types in various scenes.

The embodiment of the invention provides an automatic stack shape conversion method, which comprises the following steps:

when the pallets with the predictable stacking quantity need to be stacked, the upper-layer control system informs the conveying line to move into the pallets, sends a stacking starting instruction to the middle layer and sends information of standard stack types, current stock and stacking quantity; the middle layer inquires a target stack shape according to the standard stack shape, the current stock and the stacking number; the middle layer judges whether the current stock is 0, if not, the position of the goods on the tray is adjusted to reach a target stack shape, and then a stacking process is executed according to the target stack shape; if the current stock is 0, directly executing a stacking process according to the target stack shape;

when the pallets with unpredictable stacking quantity need to be stacked, the upper-layer control system informs the conveying line to move into the pallets, sends a stacking starting instruction to the middle layer and sends information of standard stack types and current stock; the middle layer judges whether the current stock is 0, if not, the position of the goods on the tray is adjusted to reach a standard stack shape, and then a stacking process is executed according to the standard stack shape; if the current stock is 0, directly executing a stacking process according to a standard stack type; after the stacking is finished, inquiring the current goods number of the pallet; judging whether the current stack shape is in a stable state or not according to the current number of the goods, if so, executing an ending action, otherwise, inquiring a target stack shape according to the current stack shape and the current number of the goods, and then adjusting the positions of the goods on the tray to adjust the current stack shape to the target stack shape;

when unstacking is needed, the upper-layer control system informs the conveying line to move into the tray, sends an instruction of unstacking starting to the middle layer and sends information of standard stacking types, current stock and unstacking quantity; the middle layer inquires the current stack shape according to the standard stack shape and the current stock; the middle layer sends an instruction for starting unstacking to a robot control program and sends information of standard stack types, current stock and unstacking quantity; the robot control program executes unstacking action until no subsequent task exists; and the middle layer calculates the number of the remaining goods of the current tray, judges whether the current stack type is a stable stack type or not according to the current stack type and the number of the remaining goods, adjusts the positions of the existing goods on the tray if the current stack type is not the stable stack type so as to adjust the current stack type into the stable stack type, and then unstacks the current tray.

The embodiment of the invention also provides a stack type automatic conversion device, which comprises an upper layer control system, a middle layer and a robot control program:

the upper-layer control system is used for informing the conveying line to move into the tray when the trays with the predictable stacking number need to be stacked, sending a stacking starting instruction to the middle layer and sending information of a standard stack type, a current stock and the stacking number; the middle layer is used for inquiring a target stack shape according to the standard stack shape, the current stock and the stacking number; the middle layer is used for judging whether the current stock is 0 or not, if the current stock is not 0, the position of the existing goods on the tray is adjusted to reach a target stack shape, and then a stacking process is executed according to the target stack shape; if the current stock is 0, directly executing a stacking process according to the target stack shape;

the upper-layer control system is used for informing the conveying line to move into the tray when the trays with unpredictable stacking quantity need to be stacked, sending a stacking starting instruction to the middle layer and sending information of standard stack types and current stock; the middle layer is used for judging whether the current stock is 0 or not, if the current stock is not 0, the position of the existing goods on the tray is adjusted to reach a standard stack shape, and then a stacking process is executed according to the standard stack shape; if the current stock is 0, directly executing a stacking process according to a standard stack type; after the stacking is finished, inquiring the current goods number of the pallet; judging whether the current stack shape is in a stable state or not according to the current number of the goods, if so, executing an ending action, otherwise, inquiring a target stack shape according to the current stack shape and the current number of the goods, and then adjusting the positions of the goods on the tray to adjust the current stack shape to the target stack shape;

the upper-layer control system is used for informing the conveying line to move into the tray when unstacking is needed, sending an instruction of unstacking starting to the middle layer and sending information of standard stacking types, current stock and unstacking quantity; the middle layer inquires the current stack shape according to the standard stack shape and the current stock; the middle layer is used for sending an instruction of unstacking starting to a robot control program and sending information of standard stack types, current stock and unstacking quantity; the robot control program is used for executing unstacking actions until no subsequent task exists; the middle layer is used for calculating the number of the remaining goods of the current tray, judging whether the current stacking type is the stable stacking type or not according to the current stacking type and the number of the remaining goods, adjusting the positions of the existing goods on the tray if the current stacking type is not the stable stacking type so as to adjust the current stacking type to be the stable stacking type, and then unstacking is completed.

The embodiment of the invention provides a method and a device for automatically changing a stack shape, wherein the method comprises the following steps: when the pallets with the predictable stacking number need to be stacked, the target stacking type can be inquired according to the standard stacking type, the current stock and the stacking number, and stacking is carried out according to the target stacking type; when the pallets with unpredictable stacking quantity need to be stacked, stacking can be carried out according to a standard stack shape, and after the stacking is finished, the position of the existing goods on the pallets is adjusted to enable the goods to reach a stable stack shape; when needs chop, can chop according to tearing open and chop the quantity and chop to judge when tearing open and chop and whether present buttress type is stable buttress type, if not then carry out position adjustment to remaining goods on the tray, make it reach stable buttress type. According to the embodiment of the invention, an intermediate layer can be separated, the dependence on an upper layer control system is reduced, corresponding movement instruction control is added to the robot, and the stack shape can be dynamically changed, so that the generation of unstable stack shape in various scenes is avoided.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.

Figure 1 is a schematic view of a 30-piece palletized stack;

figure 2 is a schematic of a 28-piece stack type;

FIG. 3 is a schematic flow chart of an automatic stack type conversion method according to an embodiment of the present invention.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

It will be understood that the terms "comprises" and/or "comprising," when used in this specification and the appended claims, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

It is also to be understood that the terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used in the specification of the present invention and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

It should be further understood that the term "and/or" as used in this specification and the appended claims refers to and includes any and all possible combinations of one or more of the associated listed items.

As shown in fig. 3, an automatic stack type conversion method provided by an embodiment of the present invention includes the following steps:

s1, when the pallets with the predictable stacking number need to be stacked, the upper control system informs the conveying line to move into the pallets, sends a stacking starting instruction to the middle layer and sends information of standard stack types, current stock and stacking number; the middle layer inquires a target stack shape according to the standard stack shape, the current stock and the stacking number; the middle layer judges whether the current stock is 0, if not, the position of the goods on the tray is adjusted to reach a target stack shape, and then a stacking process is executed according to the target stack shape; if the current stock is 0, directly executing a stacking process according to the target stack shape;

s2, when the pallet with unpredictable quantity needs to be palletized, the upper layer control system informs the conveying line to move into the pallet, sends a pallet start instruction to the middle layer and sends information of standard pallet types and current stock; the middle layer judges whether the current stock is 0, if not, the position of the goods on the tray is adjusted to reach a standard stack shape, and then a stacking process is executed according to the standard stack shape; if the current stock is 0, directly executing a stacking process according to a standard stack type; after the stacking is finished, inquiring the current goods number of the pallet; judging whether the current stack shape is in a stable state or not according to the current number of the goods, if so, executing an ending action, otherwise, inquiring a target stack shape according to the current stack shape and the current number of the goods, and then adjusting the positions of the goods on the tray to adjust the current stack shape to the target stack shape;

s3, when unstacking is needed, the upper control system informs the conveying line to move into the tray, sends an instruction of unstacking start to the middle layer and sends information of standard stacking type, current stock and unstacking quantity; the middle layer inquires the current stack shape according to the standard stack shape and the current stock; the middle layer sends an instruction for starting unstacking to a robot control program and sends information of standard stack types, current stock and unstacking quantity; the robot control program executes unstacking action until no subsequent task exists; and the middle layer calculates the number of the remaining goods of the current tray, judges whether the current stack type is a stable stack type or not according to the current stack type and the number of the remaining goods, adjusts the positions of the existing goods on the tray if the current stack type is not the stable stack type so as to adjust the current stack type into the stable stack type, and then unstacks the current tray.

In the above steps, S1 and S2 are for palletizing, and S3 is for unstacking.

For the palletizing, two scenarios are divided, wherein step S1 is the palletizing for the non-tail discs or the predictable number of tail discs, and step S2 is the palletizing for the unpredictable number of tail discs. Wherein the tail disc is as follows: the method is characterized by comprising the following steps of (1) indicating the last tray or a group of trays of a stacking or unstacking task, and generally indicating the last tray or a group of trays which cannot be fully stacked or unstacked and are empty; the tray or set of trays, although the last tray of a task, can be completely loaded and unloaded, and is not generally considered a tail tray.

For destacking, the embodiment of the invention generally refers to a continuous task mode of robot destacking, namely, an unstacking mode of destacking tasks is issued in batches according to equipment states instead of issuing all destacking tasks of the tray by an upper-layer control system at one time.

In the embodiment of the invention, as the robot control program can only faithfully execute the tasks submitted by the upper-layer control system, the stacking type can not be automatically modified due to different stacking numbers. The upper level control systems (typically warehouse management systems, warehouse control systems, manufacturing execution systems, etc.) are likely to not take into account the problem of unstable stackers. Even if the upper control system has corresponding function support, due to the communication limitation, the robot can only inform the robot to control the stack shape (a stable stack shape) required by the program before stacking, and the unstable stack shape is avoided by rearranging the stacking number of a plurality of trays close to the tail. Once palletization has started, the upper control system cannot modify the shape of the stack. The embodiment of the invention adds corresponding movement instruction control to the robot control process, and can dynamically change the stack shape. Meanwhile, the function is separated to form the middle layer, so that the function dependence on an upper control system is reduced.

The upper control system provides standardized pallet type information (i.e., the standard pallet type referred to in the various embodiments of the present invention), i.e., a stable pallet type of the goods when full of pallets. The intermediate layer may provide a look-up table by which it can be recorded whether a particular palletising number corresponds to a particular palletising type when the palletising is not full. If so, the manner in which how to deform from other buttress types (including other particular buttress types for which the standard buttress type corresponds) to this particular buttress type may also be recorded.

For example a 30-pack type, and when stacking 21-22 packs, it is common for a particular pack to lay a single piece of the third layer across, i.e. with reference to the 28-pack type of superordinate lay.

Because only limited stack type information is typically recorded in the upper level control system, it is not possible to adapt well to flexible stack type changes. And the changed stack shape is only related to the original stack shape and the stacking number, the embodiment of the invention can store the stack shape information in the middle layer in the form of a comparison table (corresponding table) without storing the stack shape information in an upper control system.

In the embodiment of the invention, the middle layer is used for executing relevant logic of buttress type conversion. The intermediate layer may exist in a variety of forms: as independent software, packaged as independent hardware in the form of embedded software, installed in an upper control system, integrated into a robot control program, and the like.

By adopting the embodiment of the invention, the upper-layer control system does not need to manage non-standard stack types and does not need to make matching modification. The robot control process needs to be modified in a matching manner so as to increase the goods moving process and realize the inquiry of the current goods quantity on the station tray. By the embodiment of the invention, the stability of stacking and unstacking can be realized without fillers, foreknowledge of warehousing quantity, manual intervention and modification of an upper system.

In one embodiment, the step S1 includes:

s11, the upper layer control system informs the conveying line to move into the tray, sends a stacking starting instruction to the middle layer and sends information of standard stack types, current stock and stacking quantity;

s12, judging whether the current stock is 0 or not by the middle layer, if not, entering a first goods moving process, and switching to a first stacking process after the first goods moving process is finished; if the current stock is 0, inquiring a target stack shape according to the standard stack shape, the current stock and the stacking number, and then switching to a first stacking process;

the first cargo moving process includes: inquiring the current stack type according to the standard stack type and the current stock; inquiring a target stack type according to the standard stack type, the current stock and the stacking number; judging whether the current stack shape is a target stack shape or not, if so, ending the first cargo moving process; if not, sending a notice of entering a goods moving mode to a robot control program, enabling the robot to execute goods moving and placing actions, achieving a target stack shape, and then exiting the goods moving mode;

the first palletizing process comprises: the middle layer sends a stacking starting instruction to the robot control program and sends information of a target stacking type, current stock and stacking quantity to the robot control program; when the robot control program detects a positioning signal, performing stacking actions according to a target stack shape until the stacking quantity is finished, then performing safety actions and informing the middle layer of stacking completion information; and the middle layer sends stacking completed information to the upper layer control system.

This embodiment is to the pile up neatly of the tail dish of non-tail dish, foreseeable quantity, and in this scene, either be to the pile up neatly of non-tail dish, or the pile up neatly of the tail dish of foreseeing pile up neatly quantity, whatever can all know next required pile up neatly quantity on the tray that needs the operation.

In step S11, the upper control system first notifies the conveyor line to move into the pallet, so that the robot control process controls the robot arm to stack the goods in the pallet.

The upper control system can send a stacking starting instruction to the middle layer, and since the stacking quantity can be predicted in the embodiment, the upper control system can send information of standard stacking types, current stock and stacking quantity. I.e. the cargo information includes information on standard stack types, current inventory and number of stacks.

The standard stacking type is the stable stacking type of the tray provided by the upper control system when the tray is full of goods. The current stock is the quantity of the goods on the pallet moved to the conveying line. The stacking quantity is the quantity of the goods required to be stacked at this time. For example, in the 30-piece stacking mode, if 30 empty trays start to be stacked, the stacking number is 30; for another example, in the 30-piece palletizing method, 3 pieces of goods are already secondarily palletized on the pallet, and 10 pieces of goods are ready to be palletized (namely, the number of the palletized goods is 13), so that the palletizing number is 10.

In step S12, the intermediate layer first determines whether the current stock amount is 0, and if the current stock amount is not 0, it indicates that the pallet is secondarily stacked (that is, the pallet is stacked again on the pallet having the existing goods). If the current stock is 0, the current stock indicates that an empty tray is stacked, namely, one-time stacking. The embodiment of the invention respectively processes the two situations.

If the current stock is not 0, entering a first goods moving process, and switching to a first stacking process after the first goods moving process is finished; if the current stock is 0, inquiring a target stack shape according to the standard stack shape, the current stock and the stacking quantity, and then switching to a first stacking process.

The first goods moving process aims to adjust the positions of goods existing on the tray, so that the final stacking type of the tray after the second stacking is a stable stacking type. That is, before the second palletizing process, the current pallet needs to be subjected to the palletizing type adjustment so as to be in line with the target palletizing type. Because the current style may be required for the last palletization, rather than a standard style; it is also possible that new palletization results may result in non-standard palletization types; both may be possible, but the shape of the stack is different.

Specifically, in the first cargo moving process, the middle layer firstly queries the current stack type according to the standard stack type and the current stock; from the standard shape and the inventory on the pallet, a corresponding unique stable shape can be ascertained. The current stack on the pallet is necessarily this stable stack as a result of the pallet being palletized or unstacked from the previous time. For example 30 pallets, if the current stock on the pallet is 21, the shape of this pallet shape can be known: the top piece is placed upside down in a fixed position. In the case of a standard pallet type, with a determined number of goods, a corresponding unique stable pallet type can be determined.

Inquiring a target stack type according to the standard stack type, the current stock and the stacking number; the only stable stack shape that corresponds to this is actually ascertained from the standard stack shape, the sum of the current stock on the pallet and the number of stacks (total stack when stacking is complete). And the stable stack type is taken as the target stack type of the goods on the pallet, and since the total stacking amount of the pallet is clearly known when the stacking is completed, the stable stack type can be taken as the target stack type of the goods on the pallet.

Judging whether the current stack shape is a target stack shape or not, if so, ending the first cargo moving process; if not, a notice of entering the goods moving mode is sent to the robot control program, so that the robot executes goods moving and placing actions, a target stack shape is achieved, and then the goods moving mode is exited. In the embodiment of the invention, whether the current stacking type of the tray is the target stacking type needs to be judged firstly, and if so, the position of the goods existing on the tray does not need to be adjusted, and the stacking can be directly carried out. If not, the position of the goods on the tray needs to be adjusted, and then stacking is carried out. When position adjustment is needed, a notification of entering a cargo moving mode can be sent to the robot control procedure from the middle layer, and then a cargo moving instruction is sent to the robot control procedure from the middle layer, so that the robot control procedure executes a single moving and placing action, the middle layer judges whether the movement is finished and the target stacking type is reached, if so, a notification of exiting the cargo moving mode is sent to the robot control procedure from the middle layer, so that a first cargo moving process is ended, otherwise, a cargo moving instruction is sent to the robot control procedure from the middle layer until the target stacking type is reached, and then the cargo moving mode is exited, so that the first cargo moving process is ended.

The single moving and placing action refers to one stacking and placing action of the mechanical arm. If the stacking is carried out, the goods are grabbed (or sucked, the same is applied below) from the stacking preparation position and stacked on the tray according to the position designated by the stacking mode. The quantity of the goods corresponding to one action can be changed according to the stack type and the quantity of the goods on the current tray, and the goods are not stacked one at a time. And if the goods are unstacked, the goods are grabbed from the tray and moved to a designated unstacking target station (goods conveying line). Similarly, the number of goods corresponding to one action varies according to the stack type and the number of goods on the current pallet, and is not only removed one at a time.

After the first cargo moving procedure is finished, the current stacking type on the pallet is already adjusted to the target stacking type. On the basis, secondary stacking can be carried out, namely, the first stacking process is shifted to. If the current stock is 0, stacking can be directly performed on the tray, that is, the first stacking process is directly entered, and in this scenario, firstly, the target stack type is queried according to the standard stack type, the current stock and the stacking number, so that stacking is performed according to the target stack type, and the stacking efficiency and stability are improved.

Specifically, in the first palletizing process, the middle layer sends a palletizing start instruction to the robot control program, and sends information of a target palletizing type, a current stock and a palletizing number to the robot control program.

The robot control program waits for goods to be stacked to reach the stacking waiting area, when the robot control program detects a positioning signal, the stacking action (specifically, single moving and placing action) can be executed according to a target stacking type, the robot control program judges whether the stacking is full, and if the stacking is full, the robot control program can directly execute a safety action to move the mechanical arm back to the safety area. If the stacking quantity is not completed, judging whether the stacking quantity is completed or not, if the stacking quantity is completed, executing a safety action and informing the intermediate layer of stacking completion information, and if the stacking quantity is not completed, continuing stacking until the stacking quantity is completed or the stacking quantity is completed; and finally, the middle layer sends stacking completion information to the upper layer control system.

For stacking of a non-tail disc and a predictable number of tail discs, a specific embodiment provided by the present invention is as follows (in embodiments of the present invention, "a- > B" indicates that a sends information or instructions to B):

1. upper control system- > transfer chain: and moved into the tray.

2. Upper control system- > middle layer: and informing the start of stacking, and informing the standard stack type, the current stock and the stacking number.

3. The current stock is not 0, and the goods move process (adjusting the position of the goods on the tray)

a. An intermediate layer: inquiring the current stack type according to the standard stack type and the current stock transmitted by the upper control system;

b. an intermediate layer: inquiring a target stack type according to the standard stack type, the current stock and the stacking quantity transmitted by the upper-layer control system;

c. an intermediate layer: and judging whether the current stack shape is the target stack shape. If yes, the cargo moving process is exited to step 4. If not, continue.

d. Middle layer- > robot control program: the cargo movement mode is entered.

e. Middle layer- > robot control program: and issuing a cargo moving instruction.

f. Robot control program: a single move and drop action is performed.

g. An intermediate layer: and judging whether the movement is finished or not to achieve the target stack shape. If so, continue. If not, go to step 3. e.

h. Middle layer- > robot control program: the cargo movement mode is exited.

4. Middle layer- > robot control program: and informing the start of stacking, and informing the target stack type, the current stock and the stacking number.

5. Robot control program: waiting for goods to be stacked to reach the stacking waiting area.

6. Robot control program: a single move and drop action is performed.

7. Robot control program: it is determined whether it is already code full. If yes, go to step 9. If not, continue.

8. Robot control program: it is judged whether the designated palletizing amount has been completed. If so, continue. If not, continuing the next palletizing action in the step 5.

9. Robot control program: and executing a safety action to move the mechanical arm back to the safety zone.

10. Robot control program- > middle layer: and informing that the palletizing is completed.

11. Middle layer- > upper layer control system: and informing that the palletizing is completed.

12. Upper control system- > transfer chain: the tray is removed.

In one embodiment, the step S2 includes:

s23, the upper control system informs the conveying line to move into the tray, sends a stacking starting instruction to the middle layer and sends information of a standard stack type and the current stock;

s24, judging whether the current stock is 0 or not by the middle layer, if not, entering a second cargo moving process, and switching to a second stacking process after the second cargo moving process is finished; if the current stock is 0, directly switching to a second stacking process;

the second cargo moving process includes: inquiring the current stack type according to the standard stack type and the current stock; judging whether the current stack type is a standard stack type or not, and if so, ending the second cargo moving process; if not, sending a notice of entering a goods moving mode to a robot control program, enabling the robot to execute goods moving and placing actions, achieving a standard stack shape, and then exiting the goods moving mode;

the second stacking process comprises the following steps: the middle layer sends a stacking starting instruction to the robot control program and sends information of a standard stacking type and the current stock to the robot control program; when the robot control program detects a positioning signal, the stacking action is executed according to a standard stack type until a stacking termination instruction sent by the middle layer is received, and then the safety action is executed and stacking completion information is notified to the middle layer; and the middle layer sends stacking completed information to the upper layer control system.

This embodiment is for the palletization of an unpredictable number of tail trays, and in this scenario, the upper level control system does not know the number of palletization required on the tray that needs to be operated next.

In step S23, the upper control system first notifies the conveyor line to move into the pallet, so that the robot control process controls the robot arm to stack the goods in the pallet.

The upper control system sends a stacking starting instruction to the middle layer, and since the stacking quantity cannot be predicted in the embodiment, the upper control system can send information of a standard stacking type and the current stock. I.e., the cargo information includes information of the current inventory.

Reference is made to the preceding description for the meaning of standard stackability and current inventory and no further description is given here.

In step S24, the intermediate layer first determines whether the current stock amount is 0, and if the current stock amount is not 0, it indicates that the pallet is secondarily stacked (that is, the pallet is stacked again on the pallet having the existing goods). If the current stock is 0, the current stock indicates that an empty tray is stacked, namely, one-time stacking. The embodiment of the invention respectively processes the two situations.

If the current stock is not 0, entering a second cargo moving process, and switching to a second stacking process after the second cargo moving process is finished; if the current stock is 0, the stacking quantity is not known in the embodiment, so that the first stacking process can be directly entered.

The second cargo moving process aims to adjust the position of the existing cargo on the tray, so that the final stacking type of the tray after the second stacking is a stable stacking type. That is, before the second palletizing process, the current pallet needs to be subjected to the palletizing type adjustment so as to be in accordance with the required palletizing type. Because the current style may be required for the last palletization, rather than a standard style; it is also possible that new palletization results may result in non-standard palletization types; both may be possible, but the shape of the stack is different.

Specifically, in the second cargo moving process, the middle layer firstly queries the current stack type according to the standard stack type and the current stock; from the standard stack shape and the current inventory on the pallet, the corresponding unique stable stack shape can be ascertained. As a result of the pallet being palletized or unstacked from the previous time, the current pallet shape on the pallet is necessarily a stable pallet shape. For example 30 pallets, if the current stock on the pallet is 21, the shape of this pallet shape can be known: the top piece is placed upside down in a fixed position.

Since the upper control system does not know the number to be palletized (palletizing number), the intermediate layer cannot be informed of the palletizing number in the foregoing embodiment. The middle layer can only look for a standard buttress type (usually a stable buttress type at full weight). If the stacking is not full and the stack shape is unstable, the stack shape finishing is needed. This standard stack type, in the case of the current stock, is not necessarily a stable stack type, but for continued stacking, only the goods can be put into order to this standard stack type first, and the stacking can be continued. Because the tray can not move after finishing and before the stacking is finished, the stacking type is unstable, and the risk can not be brought.

Judging whether the current stack type is a standard stack type or not, and if so, ending the second cargo moving process; if not, a notice of entering the goods moving mode is sent to the robot control program, so that the robot executes goods moving and placing actions, a standard stack shape is achieved, and then the goods moving mode is exited. In the embodiment of the invention, whether the current stacking type of the tray is the standard stacking type needs to be judged, if so, the position of the goods on the tray does not need to be adjusted, and the stacking can be directly carried out. If not, the position of the goods on the tray needs to be adjusted, and then stacking is carried out. When position adjustment is needed, the middle layer sends a notice of entering a cargo moving mode to the robot control program, and the middle layer sends a cargo moving instruction to the robot control program, so that the robot control program executes a single moving and placing action, the middle layer judges whether the movement is finished and the cargo moving mode is reached, if so, the middle layer sends a notice of exiting the cargo moving mode to the robot control program, so that a second cargo moving flow is ended, otherwise, the middle layer sends a cargo moving instruction to the robot control program until the standard stacking mode is reached, and then the cargo moving mode is exited, so that the second cargo moving flow is ended.

After the second cargo moving procedure is finished, the current stack type on the pallet is already adjusted to the standard stack type. On the basis, secondary stacking can be carried out, namely, the second stacking process is switched to. If the current inventory is 0, the pallet can be directly palletized, i.e. directly enter the second palletizing process.

Specifically, in the second stacking process, the middle layer sends a stacking start instruction to the robot control program, and sends information of a standard stacking type and a current stock to the robot control program.

The robot control program waits for goods to be stacked to reach the stacking waiting area, when the robot control program detects a positioning signal, the stacking action (specifically, single moving and placing action) can be executed according to a standard stacking type, the robot control program judges whether the goods are fully stacked, and if the goods are fully stacked, the robot control program can directly execute a safety action to move the mechanical arm back to the safety area. If the goods are not fully stacked, the next stacking action is required to be carried out continuously, when no goods exist, the upper-layer control system sends a stacking termination notification to the middle layer, the middle layer immediately notifies the robot control program of the stacking termination, and then the robot control program executes a safety action and notifies the middle layer of stacking completion information; and the middle layer sends stacking completed information to the upper layer control system.

In an embodiment, the second stacking process further includes:

after receiving a stacking termination instruction sent by the middle layer, inquiring the current quantity of the goods on the pallet;

and judging whether the current stack shape is in a stable state, if so, executing safety action and informing the information of stacking completion to the intermediate layer, otherwise, inquiring a target stack shape according to the current stack shape and the current quantity of the goods, and then entering a goods moving mode to adjust the current stack shape to the target stack shape.

In embodiments of the present invention, since an unpredictable number of tailtrays are stacked in accordance with a standard stack type, the final stack type may not be a stable stack type, i.e., may produce an unstable stack type, since the number of tail trays is unknown. Therefore, when the robot control program receives the command of the end of palletizing, the middle layer sends the command to the robot control program so as to inquire the current quantity of the goods on the pallet. Then, the middle layer judges whether the current stacking type is in a stable state, a specific current stacking type can be obtained by inquiring according to a standard stacking type and the current quantity of cargos, then judges whether the current stacking type is in a stable stacking type, if so, the middle layer can directly execute a safety action and notify the middle layer of stacking completion information, if not, a target stacking type needs to be inquired according to the current stacking type and the current quantity of cargos, the target stacking type is the required stable stacking type, and then the middle layer enters a cargo moving mode so as to adjust the current stacking type to the target stacking type.

Aiming at the stacking of tail discs with unpredictable quantity, the invention provides a specific embodiment as follows:

1. upper control system- > transfer chain: and moved into the tray.

2. Upper control system- > middle layer: and informing the start of stacking and informing the standard stack type and the current stock.

b. an intermediate layer: and judging whether the current stack shape is a standard stack shape. If yes, the cargo moving process is exited to step 4. If not, continue.

c. Middle layer- > robot control program: the cargo movement mode is entered.

d. Middle layer- > robot control program: and issuing a cargo moving instruction.

e. An intermediate layer: and judging whether the movement is finished or not to achieve a standard stack shape. If so, continue. If not, go to step 3. d.

f. Middle layer- > robot control program: the cargo movement mode is exited.

4. Middle layer- > robot control program: and informing the start of stacking and informing the standard stack type and the current stock.

5. Robot control program: and if the stacking termination signal is received, stopping the stacking process, entering a cargo moving mode, and going to the step 10. Or waiting for goods to be stacked to reach the stacking waiting area. Both of which are based on a signal received first. If both are not signaled, the system will wait continuously.

6. Robot control program: a single move and drop action is performed.

7. Robot control program: it is determined whether it is already code full. If so, go to step 10 (wait for follow-up action). If not, continuing the next palletizing action in the step 5.

8. Upper control system- > middle layer: when there is no cargo, the palletizing is notified of the end.

9. Middle layer- > robot control program: the palletization is notified of the end of palletization and the robot control program is waited to respond in step 5.

10. Middle layer- > robot control program: and inquiring the current cargo quantity of the pallet.

11. An intermediate layer: and judging whether the current stacking type is a stable stacking type. If so, go to step 16. If not, continue.

12. An intermediate layer: and inquiring the target stack type according to the current stack type and the current cargo quantity.

13. Middle layer- > robot control program: and issuing a cargo moving instruction.

14. Robot control program: a single move and drop action is performed.

15. An intermediate layer: and judging whether the movement is finished or not to achieve the target stack shape. If so, continue. If not, go to step 13.

16. Middle layer- > robot control program: and exiting the goods moving mode and simultaneously informing that the stacking is finished.

17. Robot control program: and executing a safety action to move the mechanical arm back to the safety zone.

18. Robot control program- > middle layer: and informing that the palletizing is completed.

19. Middle layer- > upper layer control system: and informing that the palletizing is completed.

20. Upper control system- > transfer chain: the tray is removed.

In particular, since the upper control system may initiate the no-good notification when the pallet stack is full, after the determination of the full pallet in step 7, it cannot directly proceed to step 17, and may wait for the middle layer to complete a series of actions until the completion of palletizing is notified (step 16), and then continue to execute step 17.

The tray finishes stacking, and either waits for the stacking to be full or waits for the goods-free notice of the upper-layer system to finish in advance. The upper control system does not pay attention to the specific stacking situation of the trays. When the upper system confirms that there is no subsequent goods, a no-goods notification is issued even if the current pallet is just full (in principle, there is no need to wait for a no-goods notification). Therefore, the process needs to prevent the interference caused by the fact that the upper control system is not informed of the goods. The full stack shape is a stable stack shape. Thus, no detection nor readjustment is required for a full stack.

In an embodiment of the invention, said performing a safety action comprises moving the robot arm back to the safety zone.

In addition, in the embodiment of the present invention, after the performing the security action, the method further includes:

and the robot control program sends stacking completion information to the middle layer.

In addition, in the embodiment of the present invention, after the middle layer sends the palletizing completion information to the upper control system, the method further includes:

the upper control system informs the conveying line to remove the tray.

The steps of the above embodiments are applicable to the various scenarios described above.

In step S3, the general idea is to perform unstacking according to information such as the number of unstacking operations, and after the unstacking operation is completed, it is further necessary to determine whether the current stacking type on the tray is a stable stacking type, and if so, the unstacking operation is completed without adjustment, and if not, the adjustment is performed, so that the current stacking type on the tray is adjusted to a stable stacking type.

Specifically, when unstacking is needed, the upper-layer control system informs the conveying line to move into the tray, sends an instruction of unstacking starting to the middle layer and sends information of standard stacking types, current stock and unstacking quantity; the middle layer inquires the current stack shape according to the standard stack shape and the current stock; the middle layer sends an instruction for starting unstacking to a robot control program and sends information of standard stack types, current stock and unstacking quantity; the robot control program executes unstacking action until no subsequent task exists; and the middle layer calculates the number of the remaining goods of the current tray, judges whether the current stacking type is a stable stacking type or not according to the current stacking type and the number of the remaining goods, enters a goods moving process to adjust the current stacking type to be the stable stacking type if the current stacking type is not the stable stacking type, and then unstacks.

For unstacking, one embodiment of the invention provides the following:

1. upper control system- > transfer chain: and moved into the tray.

2. Upper control system- > middle layer: and informing the start of unstacking, and informing the standard stack type, the current stock and the unstacking quantity of the task.

3. An intermediate layer: and inquiring the current stack type according to the standard stack type and the current stock transmitted by the upper-layer control system.

4. Middle layer- > robot control program: and informing the start of unstacking, and informing the standard stack type, the current stock and the unstacking quantity of the task.

5. Robot control program: waiting for a put zone empty signal.

6. Robot control program: a single unstacking action is performed.

7. Robot control program: it is determined whether a void has been torn open. If so, go to step 23. If not, continue.

8. Robot control program: and judging whether the unstacking quantity of the task is finished or not. If so, go to step 11 (wait for follow-up action). If not, continuing the next unstacking action in the step 5.

9. The upper control system: and detecting whether a subsequent task exists. If so, continue. If not, go to step 14.

10. Upper control system- > middle layer: and informing the number of unstacking of the new task.

11. Middle layer- > robot control program: and informing the number of unstacking of the new task.

12. Robot control program: and 5, executing a new unstacking task.

13. The upper control system: and 9, continuing to detect for the next time.

14. Upper control system- > middle layer: no subsequent tasks are notified.

15. Middle layer- > robot control program: no subsequent tasks are notified.

16. An intermediate layer: and calculating the quantity of the remaining goods of the current pallet. If the number is 0 (has been emptied), go to step 23.

17. An intermediate layer: and judging whether the current stacking type is a stable stacking type or not according to the current stacking type and the number of the remaining cargos. If so, go to step 23. If not, continue.

18. An intermediate layer: and inquiring the target stacking type according to the standard stacking type and the residual cargo quantity.

19. Middle layer- > robot control program: and issuing a cargo moving instruction.

20. Robot control program: a single move and drop action is performed.

21. An intermediate layer: and judging whether the movement is finished or not to achieve the target stack shape. If so, continue. If not, go to step 19.

22. Middle layer- > robot control program: and exiting the goods moving mode and simultaneously informing that the unstacking is finished.

23. Robot control program: and executing a safety action to move the mechanical arm back to the safety zone.

24. Robot control program- > middle layer: and informing the completion of unstacking.

25. Middle layer- > upper layer control system: and informing the completion of unstacking.

26. Upper control system- > transfer chain: the tray is removed.

It should be noted that the shape of the stacks does not change automatically due to the difference in number. The stack shape can not be automatically changed due to unstacking and stacking unless the stack shape is finished. For example, 30 packs as in figure 1, the packs were identical regardless of whether there were 30, 21 (unstable) and 15 on them. The stack shape is not directly lockingly associated with the number of items actually stacked on the pallet, but rather merely represents the maximum number of items that can be stored on the pallet, as well as the specific location of each item.

In embodiments of the invention, stabilizing the shape of the buttress is a physical experience concept. For example, when 30 pieces are stacked as in fig. 1, if the stacking number is 23-30 pieces, 13-20 pieces or 3-10 pieces, the goods are supported by each other, and are not easy to fall down during shaking, so that the stacking type is called stable stacking type. If the number of pallets is a certain number, for example 21, and the third layer is only 1 standing, it is very easy to shift or fall due to shaking.

A unique look-up table is required in the middle layer: the shape of the stack (standard), the total number of items on the pallet (specific number) of the upper control system corresponds to a target shape (stable shape at this specific number). When no record is checked in the comparison table, the standard buttress type is directly used (the standard buttress type is regarded as the stable buttress type).

In one embodiment, the upper control system is used for informing the conveying line to move into the tray, sending a stacking starting instruction to the middle layer and sending information of a standard stack type, a current stock and a stacking quantity;

the middle layer is used for judging whether the current stock is 0 or not, if the current stock is not 0, entering a first goods moving process, and switching to a first stacking process after the first goods moving process is finished; if the current stock is 0, inquiring a target stack shape according to the standard stack shape, the current stock and the stacking number, and then switching to a first stacking process;

In one embodiment, the upper control system is used for informing the conveying line to move into the tray, sending a stacking starting instruction to the middle layer and sending information of a standard stack type and the current stock;

the middle layer is used for judging whether the current stock is 0 or not, if the current stock is not 0, entering a second cargo moving process, and switching to a second stacking process after the second cargo moving process is finished; if the current stock is 0, directly switching to a second stacking process;

For details of the apparatus, reference is made to the description of the method, which is not described in detail here.

The embodiments are described in a progressive manner in the specification, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other. The device disclosed by the embodiment corresponds to the method disclosed by the embodiment, so that the description is simple, and the relevant points can be referred to the method part for description. It should be noted that, for those skilled in the art, it is possible to make various improvements and modifications to the present invention without departing from the principle of the present invention, and those improvements and modifications also fall within the scope of the claims of the present invention.

It is further noted that, in the present specification, relational terms such as first and second, and the like are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other identical elements in a process, method, article, or apparatus that comprises the element.

Claims

1. An automatic method for transforming a shape of a stack, comprising:

2. An automatic stack change method according to claim 1, wherein when a predictable number of pallets needs to be palletized, the method comprises:

the upper layer control system informs the conveying line to move into the tray, sends a stacking starting instruction to the middle layer and sends information of standard stack types, current stock and stacking quantity;

the middle layer judges whether the current stock is 0 or not, if not, the middle layer enters a first goods moving process and shifts to a first stacking process after the first goods moving process is finished; if the current stock is 0, inquiring a target stack shape according to the standard stack shape, the current stock and the stacking number, and then switching to a first stacking process;

3. An automatic stack change method according to claim 1, wherein when an unpredictable number of pallets needs to be palletized, it comprises:

the upper control system informs the conveying line to move into the tray, sends a stacking starting instruction to the middle layer and sends information of a standard stack type and the current stock;

the middle layer judges whether the current stock is 0, if not, the second goods moving process is started, and the second stacking process is switched to after the second goods moving process is finished; if the current stock is 0, directly switching to a second stacking process;

4. A method for automatic change of a palletization type according to claim 3, wherein said second palletization process further comprises:

5. A method according to any one of claims 2 to 4, wherein performing a safety action comprises moving the robotic arm back to a safety zone.

6. A method for automatic transformation of a buttress type according to any one of claims 2-4, further comprising, after performing the safety action:

7. A method for automatic change of a pile type according to any one of claims 2 to 4, wherein after the information that the middle layer has sent the pile to the upper control system, the method further comprises:

the upper control system informs the conveying line to remove the tray.

8. The stack type automatic conversion device is characterized by comprising an upper layer control system, a middle layer and a robot control program:

9. A stack-type automatic changing device according to claim 8,

the upper layer control system is used for informing the conveying line to move into the tray, sending a stacking starting instruction to the middle layer and sending information of standard stack types, current stock and stacking quantity;

10. A stack-type automatic changing device according to claim 8,

the upper layer control system is used for informing the conveying line to move into the tray, sending a stacking starting instruction to the middle layer and sending information of a standard stack type and the current stock;